Vegetable protein meat analog

ABSTRACT

The present invention relates to a process for making a vegetable base meat analog, which may be used in a variety of vegetarian food products, such as burger patties and sausages. The process of the present invention involves sequentially blending methyl cellulose into a water/ice mix to form a cream, then blending in a modified gluten, a vegetable protein product having high solubility in water and capable of forming a gel with mild heat treatment, an oil to make an emulsion base, and a modified food starch and flavoring ingredients to form a flavored emulsion base. The flavored emulsion base may be stuffed into casings, and then cooked. The flavored emulsion base, once cooked, is a vegetable base meat analog and has a high resemblance to processed meat products having improved handling properties. The addition of the flavored emulsion base and the vegetable base meat analog in vegetarian food products improves the texture, mouthfeel, and juiciness of the resulting products.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related to and claims the benefit under 35 USC §119(e) of U.S. patent application Ser. No. 10/877,744, titled VEGETABLEPROTEIN MEAT ANALOG, filed Jun. 25, 2004.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to vegetable protein products, and moreparticularly to a process for making a vegetable base meat analog.

A ground meat pattie, when cooked by baking, grilling or pan fryingloses much of its moisture and undergoes a substantial weight loss. Thisweight loss results in a obvious shrinkage of the cooked meat product.The total moisture loss in any meat due to the cooking out of thenatural juices is an inevitable consequence of the cooking process andlargely depends upon the degree of cooking.

Recent trends in food consumption show that people are becoming morehealth conscious and monitoring their food intake as the result ofrecent research into the possible effects of particular foodstuffs onhealth. Animal products are the only dietary source of cholesterol andmay contain high levels of saturated fats. This has led large numbers ofhealth professionals to recommend that the public significantly reducetheir intake of red meats. Fish and poultry have become popularsubstitutes, but vegetable protein also is increasing in popularity.Generally, vegetable protein is eaten in the form of beans or othernatural products alone or mixed with animal foodstuffs, but enrichedsources such as flours, concentrates and isolates of defatted oilseed,especially soy, have been developed for use as food ingredients.

2. Description of the Related Art

Vegetable protein based meat analog products or gelling food products,for example, cheese and yogurt, offer many health benefits to consumers.Consumer acceptance of these products is directly related toorganoleptic qualities such as texture, flavor, mouthfeel andappearance. Attempts have been made to produce vegetable proteinproducts that may be used as meat substitutes. For example, U.S. Pat.No. 4,057,656 discloses a method for preparing quick cooking foodproducts which are palatable, bland, light colored, meat-like intexture, chewable chunks when hydrated. The method involves pressingplant protein material containing 30 percent or higher protein, 5 to 10percent moisture and NSI of about 30 to 70 at a temperature sufficientto convert the moisture into steam. As a result, the plant proteinmaterial is rendered partially or substantially bland.

U.S. Pat. Nos. 4,943,441 and 5,068,117 disclose methods of processingwhole soybeans to produce discrete, irregularly-shaped chunks or piecesof textured proteinaceous material which are free from off flavors andodors and have a meat-like texture and appearance. The methods involveacidifying whole soybeans and grinding in aqueous medium to provide anaqueous slurry or dough of soybean particles, which is passed throughhigh temperature pressurized steam under conditions which effecttexturization of the soy protein in the form of discrete chunks orpieces. The texturized pieces are dried and re-hydrated for use in awide variety of food products. Additives such as flavoring, coloring,fat, seasoning and other proteinaceous materials may be incorporated inthe texturized soy protein pieces.

The above-mentioned meat-like vegetable protein products may not besuitable as protein sources for gel-based food products like thoseuseful in pickling brines, which must have good gel forming propertiesat relatively low cooking temperatures and good water and fat bindingproperties. Typically, vegetable proteins and combinations of vegetableproteins such as vital wheat gluten and soy protein isolate will formviscous mixes, prior to cooking, which are difficult to handle inpumping and forming equipment. Also, the cooked products from theseprotein sources are typically significantly different in chewiness or“bite” from the natural texture of processed meat products or gelledfood products.

U.S. Pat. No. 5,663,058 discloses a process for producing a soybeanprotein material having taste, color and water-dispersibility suitablefor use as a pickling solution at high concentrations and in viscousliquid foods such as soup. The process comprises the steps ofhydrolyzing soybean protein, emulsifying an oil-and-fat ingredient withthe soybean protein and drying the mixture.

There is a need for a better quality vegetable protein meat analog, thatcan be used in a wide variety of vegetarian food products.

SUMMARY OF THE INVENTION

The present invention relates to a process for making a vegetable basemeat analog comprising the steps of:

adding methyl cellulose into a water/ice mix and sequentially blendingmethyl cellulose and water/ice mix to form a cream;

blending in a modified gluten;

blending in a vegetable protein product having high solubility in waterand capable of forming a gel with mild heat treatment, forming a proteinmixture;

blending in oil to make an emulsion base;

blending in a modified food starch and flavoring ingredients to form aflavored emulsion base; and

cooking the flavored emulsion base to make a vegetable base meat analog.

Alternatively, the flavored emulsion base is stuffed into waterimpermeable casings prior to the cooking step.

The invention also relates to a process for making vegetable burgerpatties comprising the steps of:

mixing vegetable base meat analog pieces with at least one food bindingcomponent, flavored emulsion base, methyl cellulose, a carrageenan gelmixture, and flavoring ingredients; and

shaping the mixture into patties.

DETAILED DESCRIPTION

Vegetable burger patties satisfy the health conscious needs ofconsumers. However, typically vegetable burger patties are made in a“one step” process and as such, when these patties are cooked, there isa significant weight loss since the moisture, as water, is cooked out.This invention relates to a “two step” process wherein in the first stepa flavored emulsion base and a vegetable base meat analog are prepared.These two components from the first step are combined in the second stepwith other components to produce a pattie that maintains much of itsoriginal weight upon cooking. As such, a pattie made by the two stepprocess of the present invention is juicier than a pattie made by a onestep process.

In one embodiment of the present invention, the process for making thevegetable base meat analog includes the steps of: adding methylcellulose into a water/ice mix and sequentially blending methylcellulose and water/ice mix to form a cream; blending in a modifiedgluten, blending in a vegetable protein product having high solubilityin water and capable of forming a gel with mild heat treatment forming aprotein mixture; blending in an oil to form an emulsion base; blendingin a modified food starch and flavoring ingredients; to form a flavoredemulsion base; and cooking the flavored emulsion base to produce avegetable base meat analog. Alternatively, the flavored emulsion base isstuffed into water impermeable casings prior to the cooking step.

A suitable modified gluten includes vital wheat gluten. The vegetableprotein product is derived from soy or other plant protein such as corn,or dry beans. The modified food starch, which serves as a thickeningcomponent, is derived from any plant such as corn, potato or rice. Anyvegetable oil such as soybean oil, canola oil, corn oil, or peanut oilis suitable. The flavoring ingredients comprise at least one of asweetener, spice, salt, beef flavor, garlic powder, or a coloring dye.The flavored emulsion base contains the vegetable protein product, oil,modified food starch, methyl cellulose, and flavoring ingredients.

In one specific embodiment, the step of cooking involves heating to atemperature of about 87.8° C. (190° F.) to about 90.6° C. (195° F.).

In another embodiment, the process of the present invention includes thesteps of cooling the vegetable base meat analog to about 4.4° C. (40°F.); and grinding the cooked vegetable base meat analog into vegetablebase meat analog pieces or particles. The vegetable base meat analogpieces may have any desired sizes. Preferably the pieces have a diameterof about 3 to 12 millimeters.

The present invention further provides a vegetable base meat analog orthe vegetable base meat analog pieces produced according to the processdescribed herein.

In another embodiment, the process of the invention includes the step ofproducing vegetable burger patties, by mixing the vegetable base meatanalog pieces with at least one food binding component, flavoredemulsion base, methyl cellulose, carrageenan gel, and flavoringingredients; and shaping the mixture into patties. An example of a foodbinding component includes a soy concentrate.

The present invention includes vegetable burger patties and vegetariansausages prepared according to the process described herein.

The embodiment disclosed below is not intended to be exhaustive or limitthe invention to the precise form disclosed in the following detaileddescription. Rather, the embodiment is chosen and described so thatothers skilled in the art may utilize its teachings.

The present invention relates to a process for making a vegetable basemeat analog that has meat-like texture, and improved mouthfeel andjuiciness. The vegetable base meat analog is made from a vegetableprotein product that is highly water soluble, highly dispersible, andcapable of forming a gel at a low heat treatment. The characteristics ofcomplete gel formation at temperatures relevant for meat pasteurizationgenerates a very firm and cohesive overall meat structure, excellentlysuited for slicing. Specifically, the vegetable protein product forms agel at a temperature of between 60 and 105° C., preferably at atemperature of between 70 and 90° C. It has a protein content between60% and 82% moisture free basis, and an NSI (nitrogen solubility index)of between 50 and 100. Further, the vegetable protein product ischaracterized by having a viscosity of 5-50 centipoises, preferably 5-25centipoises, measured on a 10% dispersion by weight, in water.Preferably the vegetable protein product is derived from soy or otherplant protein such as canola, peanuts or dry beans. Any known method maybe used to product such vegetable protein product. For example, U.S.patent application Ser. No. 10/050,532, hereby fully incorporated byreference, discloses a method comprising the steps of: dispersing apurified protein having high PDI (Protein Dispersibility Index) in wateraround neutral pH; extracting the dispersion; removing the insolublefraction; optionally lowering the pH of the supernatant fraction to 5.0;neutralizing; optionally removing low molecular weight solubles by ultrafiltration; treating the vegetable protein product, optionally in a jetcooker; cooling; and spray drying. The dried vegetable protein productcan then be used in the process of making the vegetable base meatanalog.

The process of the present invention involves first adding 1-3 wt. %methyl cellulose to a 45-65 wt. % water/ice mix and blending the methylcellulose and water/ice mix until the blend has a consistency of ashaving cream. The water/ice mix contains about equal amounts of waterand ice. Other proportions of water and ice may also be suitable as longas the temperature during the process is kept below the point in whichthe mixture becomes hardened. Blending is accomplished by using anycommercially available blender or bowl cutter. The blending process maybe initiated with a low chopping speed to prevent spilling over. Aftermethylcellulose is fully dispersed, the chopping speed may be increased.Chopping continues at a high speed until a creamy blend is obtained.

Then, 3-10 wt. % of modified gluten such as vital wheat gluten (MidwestGrain Products, Inc., Atchison, Kans.) is added to the methylcellulosecream. Chopping continues in the same manner as described above for afew minutes until all the gluten is blended well in the cream.

Next, 10-20 wt. % of a vegetable protein product with high watersolubility and further, the capability of forming a gel with mild heattreatment, as describe above, is blended into the methylcellulose creamto form a protein mixture. A suitable vegetable protein product that hasutility in the present invention is Alpha® 5800 soy protein concentrate,available from Solae, St. Louis, Mo. 63188. Preferably the vegetableprotein product may also have high dispersibility such as Alpha® 5812soy protein concentrate. Chopping may be continued for a few minutesuntil the vegetable protein product is dispersed, and well blended.

The next step is to add 10-15 wt. % oil into the methyl cellulose creamto produce an emulsion base. Suitable oils comprise soy oil, canola oil,corn oil, or peanut oil. Chopping continues in the manner set forthabove.

The following step is to blend in 5-10 wt. % of a modified starchfollowed by 5-8 wt. % of flavoring ingredients comprising a sweetenersuch as dextrose or sucrose, salt, spice, or food coloring. Theflavoring ingredient may be added one at a time, while choppingcontinues as describe above. Additional water/ice mix may also be addedto reduce stiffness of the flavored emulsion base. The flavored emulsionbase is then stuffed into casings, which are either natural orartificial, edible or non-edible casings. Subsequently, the stuffedemulsion base may be cooked until the temperature of the core reaches87.8° C. (190° F.) to about 90.° C. (195° F.). The resulting product isan vegetable base meat analog that is easily sliceable.

The process of the present invention may include cooling the vegetablebase meat analog to about 4.4° C. (40° F.), before slicing or grindingthe cooked vegetable base meat analog into vegetable base meat analogpieces. Any desired sizes may be produced, depending on the desired typeof food products. For making vegetarian burger patties, the vegetablebase meat analog pieces have a diameter of about 3 to about 12 mm.

A specific example of the process for making a flavored emulsion base,vegetable base meat analog and vegetable base meat analog pieces isdemonstrated in Example 1.

The present invention further provides a process for making vegetableburger patties, using both the flavored emulsion base and the vegetablebase meat analog. Generally, the process involves mixing together 15-25wt. % of the flavored emulsion base, 5-20 wt. % of the vegetable basemeat analog pieces, 50-75 wt. % at least one food binding component,0.1-1 wt. % of methyl cellulose, 7-12 wt. % of carrageenan gel mixture,and 0.01-0.25 wt. % of flavoring ingredients. The vegetable burgermixture is subsequently shaped into patties, having any desired sizes.

Known food binding components comprise cracker crumbs, toasted wheatcrumbs, modified starches, milk proteins, wheat flour, or a proteinconcentrate. In a specific formula demonstrated in Example 2, extrudedproducts of protein concentrate of Solae, St. Louis, Mo. 63188(originally Central Soya, Fort Wayne, Ind.) having registered names:RESPONSE® 4402 soy protein concentrate and RESPONSE® 4320 soy proteinconcentrate are used as food binding components. RESPONSE 4402 andRESPONSE 4320 are granular in structure, with a 70% protein content.Adding these protein products to the formula improves the texture of theburger and reduces flaring on gas grills.

The carrageenan gel mixture is a gel mixture that helps preserve themeat-like texture and juiciness of the burger patties. The carrageenangel mixture may be prepared using a variety of formulas. A specificexample of the process for making carrageenan gel mixture isdemonstrated in EXAMPLE 3. The burger patties may be par fried for about30 seconds in 176.7° C. (350° F.) cooking oil. The cooking temperatureand cooking time vary according to the thickness of the patties. Thecooking oil is any suitable vegetable oil including corn oil and peanutoil.

Further, the present invention provides a process for making vegetariansausage. This instant process follows relatively the same steps asdescribed for the process of making the flavored emulsion base meat.However, relatively more water/ice mix is used in the initial step ofblending methylcellulose into water/ice mix (about 98% of totalwater/ice mix) is used. The rest of the water/ice mix is added with thedry ingredients.

After blending the gluten into the methylcellulose cream, a vegetableprotein product, a modified starch, an oil, and flavoring ingredientsare added according to the steps described for making the emulsion basemeat analog. The flavored emulsion base is then stuffed into sausagecasings.

An example of a specific process for making vegetarian sausage isdemonstrated in Example 4. According to Example 4, the modified starchused in this instant process is POLARTEX 06734, which is a product ofCargill, Minneapolis, Minn. POLARTEX 06734 is a stable modifiedcornstarch that is used as a thickener. Further, the flavoringingredients include beef flavor 535557 (Givaudan Roure, Cincinnati,Ohio).

The present invention is outlined in the following examples, which areonly an illustration and which are in no way meant to limit the scope ofthe invention. It is to be understood that the formula provided hereinmay be modified in many ways. For example, the amounts of oil orflavoring ingredients may vary. Some flavoring ingredients may beomitted or additional flavors may be added. For instance, a chicken or apork flavor may replace the beef flavor.

EXAMPLE 1 Process and Formula for Making an Emulsion Base Meat Analog

A water/ice mix is first prepared by adding equal amounts of ice andwater together to make a 50/50 water/ice mix. The total amount of thewater/ice mix required and amounts of ingredients in this example iscalculated based on the formula presented in Table I. About 90% of totalamount of water/ice mix is added to a bowl cutter (Meissner cutter),followed by 1.5 wt. % of methylcellulose. It is preferred thatmethylcellulose with a high gelling property, such as METHOCEL of DowChemical Co., Midland, Mich., be used. Chopping motion is initiated at alow knife speed, until the methylcellulose is fully dispersed. Then, theknife speed is increased to a full speed or about 3600 rpm. After 3-5minutes, methylcellulose increases in volume and has a consistencysimilar to a shaving cream. A calculated amount of vital wheat gluten asindicated in Table I is added to the methylcellulose cream. Choppingstarts at a low knife speed and increases to a full speed after thevital wheat gluten is completely dispersed. Chopping continues forapproximately 2-4 minutes. Then, a calculated amount (16 wt. %) ofvegetable protein product is blended into the protein mixture with thechopping motion. Preferably, the vegetable protein product has highwater solubility and is capable of forming a gel with mild heattreatment. After approximately 2-3 minutes, 12.5 wt. % of soy oil orcanola oil is added. Other oils such as corn oil and peanut oil may alsobe used. Chopping continues at a low speed until the oil is completelydispersed, and at a full speed until a homogenous mixture is formed.Then, all other dry ingredients, including the 2.50 wt. % of modifiedstarch (B990), 0.50 wt. % of Dextrose, 5.0 wt. % of spice and 0.25 wt. %of coloring material are added, one by one, with the rest of thewater/ice mix (10%). Chopping continues under vacuum, for about 3-4minutes, or until a homogeneous mixture of flavored emulsion base isobtained. The flavored emulsion base may be placed in a water tightcontainer or stuffed into moisture impermeable casings, which may bemade of plastic or cellulose. The flavored emulsion base may be cookedin an oil bath continuous oven until the core temperature reaches about87.8° C. (190° F.) to about 90.6° C. (195° F.). The cooked product maybe subsequently cooled to about 4.4° C. (40° F.), before the casings areremoved. The cooked vegetable base meat analog may be sliced or choppedto small particles, preferably, about 3 to 12 mm in diameter to givevegetable base meat analog pieces. The flavored emulsion base orvegetable base meat analog pieces may be incorporated into a variety ofvegetarian food products to improve the texture, mouthfeel and juicinessof the vegetarian food products. TABLE I Formula for making a flavoremulsion base/vegetable base meat analog. Ingredients wt. % Ice/Water55.75 Vegetable Protein Product 16.0 Vital Wheat Gluten¹ 6.0 Soy/canolasalad oil 12.5 Modified Starch B990² 2.5 Dextrose 0.5 Methylcellulose³1.5 Spice 5.0 Color 0.25 Total 100.0¹Midwest Grain Products, Inc.,²Grain Processing Corp.,³Dow Chemical Co., Midland, MI

EXAMPLE 2 Process and Formula for Making Vegetable Burger Patties

Dry extruded soy protein concentrates such as RESPONSE 4402 and RESPONSE4320 (registered soy protein products of Solae, originally Central SoyaCo) are hydrated with water at a ratio of two parts water to one partsoy protein product. Then 30 wt. % of hydrated RESPONSE 4402 and 30 wt.% of hydrated RESPONSE 4320 are mixed with 20 wt. % of the mixture offlavored emulsion base as prepared in Example 1. After the ingredientsare mixed together, a calculated amount of methylcellulose (0.25 wt. %)is added to the mixture, along with the spice (see Table II). Then thevegetable base meat analog pieces produced by the process demonstratedin Example 1 are slowly added along with carrageenan gel mixture (seeExample 3) to form a vegetable burger mixture. The vegetable burgermixture is then shaped into burger patties. Subsequently, the vegetableburger patties may be thoroughly cooked or par fried in 176.7° C. (350°F.) cooking oil for about 30 seconds, and immediately cooled down,frozen and packaged. TABLE II Formula for burger patties Ingredients wt.% Hydrated Response 4402 30.0 Hydrated Response 4320 30.0 Vegetable BaseMeat Analog Pieces 10.0 Flavored Emulsion Base 20.0 Carrageenan Gel 9.7Methylcellulose 0.25 Spice 0.05 Total 100.0

EXAMPLE 3 Process and Formula for Making Carrageenan Gel Mixture

The process involves mixing together 1.0 wt. % of Danisco Carrageenan860 (Danisco, Copenhagen, Denmark) with 0.35 wt. % of Danisco LocustBean Gum, and 4.0 wt. % spice, and then adding 94.65 wt. % water. Themixture is heated to about 85° C. (185° F.) with continuous agitation.Then an amount of boiling water is added back to obtain the original 100wt. %. The mixture may be cooled or refrigerated for about 24 hours toform a gel before adding to the emulsion base mixture as described inExample 2.

EXAMPLE 4 Process and Formula for Making Vegetarian Sausage

A calculate amount of water/ice (50/50) mix is prepared (see Table III).About 98 wt. % of total amount of water/ice mix is added to a bowlcutter, followed by 1.5 wt. % of high gelling methylcellulose. Choppingmotion is initiated at a low knife speed, until methylcellulose is fullydispersed, after which the knife speed is increased to a full speed orabout 3600 rpm. After 3-5 minutes, methylcellulose increases in volume,having a consistency similar to a shaving cream. About 6.0 wt. % ofvital wheat gluten is added to the methylcellulose cream. Choppingstarts at a low knife speed and increases to a full speed after thevital wheat gluten is completely dispersed. Chopping continues forapproximately 2-4 minutes. Then, about 16.0 wt. % of a vegetable proteinproduct is blended into the protein mixture with chopping in the mannerdescribed herein. Preferably, the protein product is a soy protein thathas high solubility in water and capable of forming a gel with mild heattreatment. After approximately 2-3 minutes, 12.5 wt. % soy or canola oilis added. Chopping continues at a low speed until the oil is completelydispersed and then at a full speed until a homogenous mixture is formed.Then, all other dry ingredients, including 2.5 wt. % modified starch(C*Polartex 06734), 0.50 wt. % dextrose, 5.0 wt. % spice and 0.25 wt. %of coloring material are added, one by one. The rest of the water/icemix (2%) is then added to soften the mixture. Chopping continues in themanner described herein, under vacuum (1-9 Bar), for about 3-4 minutes,or until a homogeneous mixture is obtained. The flavored emulsion baseis stuffed into water impermeable or semi permeable casings which may beremoved later, or any suitable edible sausage casings. The stuffedemulsion base may be cooked until the core temperature reaches 87.8° C.(190° F.) to about 90° C. (195° F.). The resulting product is anvegetable base sausage that has a meat-like texture and good mouthfeel.TABLE III Formula for a vegetarian sausage Ingredient wt. % Ice/Water57.55 Vegetable Protein Product 16.0 Modified Gluten¹ 6.0 Soy/canolasalad oil 12.5 C*Polartex 06734² 2.5 Dextrose 0.5 Methylcellulose 1.5Beef Flavor 535557³ 2.75 Salt 0.5 Garlic powder 0.2 Total 100.0¹Midwest Grain Products, Inc.,²Cerestar,³Givaudan Roure

While this invention has been described as having an exemplary design,the present invention may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

1. A process for making vegetable burger patties comprising the stepsof: mixing vegetable base meat analog pieces with at least one foodbinding component, flavored emulsion base, methyl cellulose, acarrageenan gel mixture, and flavoring ingredients; and shaping themixture into patties.
 2. The process of claim I, further comprising thestep of: cooking the patties.
 3. The process of claim 2, furthercomprising the step of: freezing the cooked patties.
 4. The process ofclaim 1, wherein the at least one food binding component comprisescracker crumbs, toasted wheat crumbs, modified starches, milk proteins,wheat flour, mustard or a hydrated soy protein product.
 5. The processof claim 4, wherein the food binding component is a hydrated soy proteinproduct that comprises soy protein concentrate.
 6. The process of claim2, wherein the cooking step involves heating for 30 seconds, in oil, ata temperature of about 176° C. (350° F.).
 7. The process of claim 1,wherein the flavoring ingredients comprise a sweetener, salt, spices,beef flavor, chicken flavor or pork flavor.